Printing-plate matrix and method of making the same



Oct. 23, 1928. 1,688,646

E. E. NOVOTNY PRINTING PLATE MATRIX AND METHOD OF MAKING THE SAMEOriginal Filed Feb. 9, 1926 4 Sheets-Sh t, 1

18 7/ V r) A $177 /777 flm I TTORNEYS Oct. 23, 1928.

E. E. NOVOTNY original Filed 9, 1926 4 Sheets-Sheet 2 Oct. 23, 1928. 71,688,646

E. E. NOVOTNY PRINTING PLATE MATRIX AND METHOD OF MAKING THE SAMEOriginal File Fe 1926 4 Sheets-Sheet 5 gil 6.

TTORNE Y.

Oct. 23, 1928.

E. E. NOVOTNY PRINTING PLATE MATRIX AND METHOD OF MAKING THE SAME 4Sheets-Sheet 4 Original Filed Feb. 9, 1926 [WI/ZWNTOR.

BY "W4 ATTORNEY Patented Oct. 23, 1928.

UNITED STATES EMIL E. NOVOTNY, OF PHILADELPHIA, PENNSYLVANIA, ASSIGNOBT0 JOHN STbGDELL STOKES, OF SPRING VALLEY FARMS, HUNTINGTON VALLEY POSTOI 'FICE, PENN- SYLVAN IA.

PRINTING-PLATE MATRIX AND METHOD or MAKING THE SAME.

Original application filed February 9, 1926, Serial No. 87,111. Dividedand thll application filed November 19, 1926.

This invention relates to a printing plate matrix and method ofmanufacturing the same. In the present instance I describe a method forthe production of a printing plate matrix, but I wish it to beunderstood that it is not limited in its useful application to thisparticular purpose as I may, for example, produce by the practice of myinvention printing plates for use in the printing art.

The present application is a division of my eopending application,Serial No. 87,111, filed February 9, 1 926, for printing plate andmethod of making the same.

My method of producing a printing plate matrix is directed to the makingof a structure which lacks homogeneous qualities. I wish to have aprinting plate matrix dissimilar from the usual lead and wax matrices inuse at the presenttime. as it is extremely difiicult to reproduce asolid homogeneous metallic matrix from a composite body of type andetchings without damage to the type. I wish to have the sprayed matrixlack homogeneous qualities in order that the matrix may be readilyleveled without distortion as there is a tendency for the sprayed metaldeposit to assume a concave curve during the spraying operation unlessthe sprayed coating is cooled in the manner to be described later.Furthermore, a printing plate matrix lacking homogeneous qualities maybe readily curved when heated to assume the shape of a curved matrix ormold where it is to be used for the production of curved shells orplates. As, for example, when a matrix which is first made of a solidmetal in a flat condition is subsequently curved, considerabledistortion takes place and there is a non-uniform elongation resultingin inaccuracies from a dimensional and register standpoint. Furthermore.the dimension in height to paper as reproduced in the matrix may havecertain high or low portions and these may readily be brought to theregularities and irregularities required for printing by mealns ofsuitable leveling or make-ready where the matrix is of a more or lessflexible or plastic nature. My aim, also, is to produce a printing platematrix such as may be made by an inexperienced operator through the useof equipmentaud methods eo-ordinated to pro- 'niatrix, compression ofthis kind Serial No. 149,451.

duce a product of high finish, great accuracy,

.but lacking the solid homogeneous qualities of either the lead mold orthe wax matrix.

This lack of homogeneous qualities permits a graduated or predeterminedpressure within certain localized areas as the requirements of the workcall for. With a solid homogeneous distortion as there will be a flow mmthe high pressure areas as is well understood.

After long experimentation with eutectic alloys in the form of foil andplastic metal, I have discovered that an alloy such as foundry type,monotype orother similar metals including various alloys, includingmetals such as lead, tin and antimony, is most useful for my purpose.These alloys when applied to a suitable original by means of a metallicspray properly adjusted form a structure which is not homogeneous, thepar ticles of which are combined during the operation of spraying into amore or less open structure. These particles upon striking the surfaceof a properly prepared original are caused to deposit thereon, without,rebound therefrom, and form small, thin, scalelike portions. Theseportions are apparently 0xidized on their faces. thus preventing theformation of a solid homogeneous welding action. Furthermore, thesealloys evidently throw out some of their heavier or lower meltingcomponents while traveling underthe high Velocity of the spray, andtheseroduces lower melting components make it possible 1 to subsequentlysoften the formed matrix sheet so it may be readily leveled, curved orcorrected without destroying the face forming portion of the same. Thusthese components evidently promote the cementing of the particles,resulting in a relatively flexible structure upon heating to a pointwell below the melting point of the alloy used.

A printing plate matrix made by my method. wherein an alloy of foundrytype metal was used having a melting point of approximately 650 F., wasplaced over a con;

vex curved turtle heated to a temperature of approximately 400 F., tookthe curveof this turtle with practically no measurable distortion andfitted the turtle perfectly. Upon cooling, while supported in thismanner, the printing plate matrix retained 1ts shape and was immediatelyavailable for the productlon of curved shells or for the molding ofcurved printing plates therein. A solid homogeneous matrix made bycasting as in the stereoand strains when curving a printing plate matrixmadeof my non-homogeneous metal.

A commercial electrotype and stereotype were substituted for the foundrytype metal and a suitable curve could not be obtained without actuallysoftening or melting the entire body of such printing plate matrix. Thissame metal, however, when sprayed into a nonhomogeneous structure willcurve satisfactorily. When leveling to a standard height to paper andproviding a suitable level base having the regularities orirregularities re-,

quired and placing such printing plate matrix in suitable position onsuch base and heating said matrix to the point where plasticity occurs.the matrix will seek its own level without melting and without unduedistortion. Of course, a slight amount of pressure is always desirablefor both the leveling and curving operations and therefore I preferablyprovide alight pressure for this purpose.

It is advantageous to provide a suitable cooling means either betweensubsequent thin applications of sprayed films or preferably immediatelyfollowing the area being sprayed in order not to unduly soften, distort,or buckle the delicate matrix face. This I provide by means of an airnozzle which follows in the path of the spray nozzle and removes withrapidity a large amount of the heat carried by the sprayed particles andby the heat ed air if it is used. I prefer at times to humidify the airin order that a greater and quicker cooling action may thus be secured.

My non-homogeneous sprayed metallic matrix may be produced withoutapplying pressure to the original matter, which permits of thereproduction of matrices from delicate originals, and as this metallicmatrix requires no special treatment to insure electroconductivity, theresulting original therefrom will have all the details such as would beobtained through the use of a lead mold without the technical objectionsto the high pressure necessary for the production of a solid metalliematrix. For certain metallic originals,

however, it is quite desirable to provide a thin film of wax or Canadabalsamto the surface of such originals in order to provide a footing forthe sprayed particles while being applied-thereon. This tacky film-ispreferably applied in .a very weak solution in order that it be thin andtherefore not affect the fidelity of the reproduction and that it maypresent a smooth polished surface.

The use of alloys, as previously mentioned, is very desirable where amatrix having high plasticity is to be made. It is, however, to eunderstood that I may make In matrix of any suitable sprayable materiauseful for my purpose, or that other metallic alloys or metals may besubstituted therefor. For certain cheap advertising plates it does notmatter' greatly whether there is a variation in height to paper andtherefore I may use for my matrix other suitable metals as, for ex 3ample, aluminum. A finev metallic spray is, essential for the faceforming portions of the printing plate matrix. This is obtained bysetting the air and metal outlet nozzles close together. A fine spray,however, can be applied but slowly and for this and other technicalreasons it is preferable to have more than one nozzle in order that afine spray may first be applied and that this may subsequently befollowed b a relatively I coarse and more quickly app led body orbacking portion. With the adjustable nozzle employed, however, onenozzle may be used for both purposes as by operating upon a batch oforiginals and applylng a facing coat m0 thereon and subsequentlyadjusting the nozzle for a coarse spray and applying the backlng sectionthereon. Likewise, a plurality of finely adjusted spray nozzles may beused, and if desirable a plurality of coarse spray nozzles may also beprovided in order to cover a larger area simultaneously.-

The fine spray portions may be composed of different alloys or, for thatmatter, formed of a tough wearing material such as, for example,aluminum. copper or nickel, and this may subsequently be backed wit-hafine spray and a coarse spray application or in some instances the finespray backing' may be omitted.

The application of tough films to the face may be done by subjecting thesprayed matrix to a subsequent electrolytic deposit. This harder facebacked up with a nonhomogeneous metal offers advantages such as are notpresent in the solid homogeneous metal plate matrices for varioustechnical reasons previously explained. Furthermore, the face section ishard and not so readily damaged through pressure when being leveled orcurved whereas the body portion when heated well below its melting pointwill assume a plastic condition without undue elongation or distortion.This protection of a harderface, whether applied by a spray or alloy, afine sprayed face section being first applied and this beingsubsequently backed with a coarse sprayed backing section and anendurance test was made under actual printing conditions on coatedstock. These plates have shown a production under fine printingconditions of over three hundred thousand high grade impressions. Thesetests show conclusively that the plates are capable of standing longruns and that the sprayed metallic surface because of its lackofhomogeneous qualities wears longer than foun ry type and stands upabout as well as a nickelfaced electrotype.

In the accompanying drawings- Fig. 1 shows a cross sectional view of awax original supported in a suitable pan.

Fig. 2 shows a cross sectional view of a metallic original having a waxcoating applied thereon.

Fig. 3 is a perspective view showing the apparatus in position to beemployed in spraying against the face of a suitable original.

Fig. 4 is a cross sectional view showing a printing plate matrix made bymy method wherein a fine facing spray is first applied and which issubsequently backed with a coarser sprayed body forming sectionapparatusand matrix in position for levcling.

Fig. 7 is a perspective view showing the apparatus used and printingplate matrix in position thereon after having been curved.

In operating my invention I provide, a suitable original as shown inFig. 1 and indicated as an entirety by M. This original may be formed inany suitable manner as by means of the composition 1 in the pan P, theface forming portion being indicated at 2.

Another form of original used for my purpose is shown in Fig. 2 and isindicated as an entirety by M. At 2, I indicate the face forming portionof such original and the application of the adherent or waxy material isindicated at 3. This waxy material may consist of a weak solution of saybeeswax or Canada balsam in a suitable solvent.

Fig. 3 shows the apparatus in'its simplest form, illustrating the methodof operation upon the original M which is supported on a suitablemovable carriage C traveling upon tracks T. This carriage gives bothlongitudinal and transverse motion by means of the arms 5 and 6. Thisprovides a suitable means for maintaining a relatively fixed distancebetween the original M and the metal spray nozzle S.v

' The metal is contained in the furnace or melting pot F which is heatedby suitable means as by the electrical heating unit terminating in theleads indicated at 7. When foundry type metal is used this has a meltingpoint of approximately 650 F. and it is preferably heated to atemperature not. to exceed 850 F. The molten metal is controlled bymeans of a plu valve indicated by the screw and knob terminus thereof at8. The metal issues from the nozzle S, the nozzle being sufficientlyheated by the excess heat carried by the molten metal and is vaporizedinto a fine spray by the air nozzle A which is made adjustable by meansof the adjustment device indicated as an entirety at 9, asupply ofheated air being conducted thereto by pipe 10, the heating of the airbeing accomplished through the use of the heater shown as an entirety atH consisting of coils 11, operating in the zone of a suitable source ofheat as at 12. The nozzle S, I find should have an opening not greatlyexceeding a diameter of .020"

whereas the nozzle A for the air is considerably larger but preferablyshould not greatly exceed a diameter of .070.

A suitable cooling means is provided by means of the cold air nozzle .A'connected to the pipe 13, and if at times a small amount of water isuseful this is provided by means of the water nozzle W terminating inthe pipe 14.

The spraying apparatus in Fig. 3 is suitably hooded as by means of thehood conventionally shown at H terminating in a-suction fan openingindicated at 15 which may be at either the top or the bottom oft-hishooded device, suitable doors being provided at 16. The lower section ofthis hood H serves to retain any dust particles which may settle andwhich may'not be removed through the opening 15 by means of the fan andcyclone receptacle (not shown), this cyclone receptacle serving todeposit any metallic particles which may be carried over by the air in amanner already well known.

In Fig. 4 I show the completed matrix indicated as an entirety by P.This printing plate matrix consists of a facing of finer sprayedparticles indicated at 17 ,forming the highly polished face 18 and thecoarser sprayed or less homogeneous particles indicated at 19. The backportion of such matrix has been shaved as indicated at 20.

Fig. 5 indicates a printing plate matrix very similar to that shown inFig. 4 wherein the printing plate matrix again is indicated as anentirety by P. The printing face forming section is indicated at 18consisting of sprayed matrices.

a tougher metal which may be either applied as a spray or 'which may beappl1ed subsequently as an electrolytic coating. Thls may be followedoptionally with the finer sprayed facing section 17 and the coarsersprayed backing section 19, the back thereof being again shoWn at 20.

In Fig. 6 I show the levellng apparatus indicated as an entirety by Lsupported on a suitable stand or base. This leveling device L consistsof a level surface plate section S which is heated'asconventionallyshown by the gas cock at 21. As stated previously, this base is soheated that the printing plate matrix will quickly assume a temperatureof approximately 400 to 500 F., the matrix lying upon its back againstthe polished surface plate S" and proper pressure is applied by means ofthe screw 22 operating against the platen 23. A suitable resilientblanket (not shown) is preferably placed against the face of theprinting plate matrix and the, lower section of the pressure platen 23,in order that a light ressure may be applied and that any irreguiarities may be taken up in this blanket. A suitable cooling means isprovided by means of the inlet hole 24 and outlet hole 25, for theadmission of cooling water in order that the matrix may be quicklycooled by circulating cooling water in a properly cored cooling plate.

In Fig: 7 I show an apparatus in conventional form for the purpose ofcurving my This apparatus is indicated as an entirety by B which issupported on a suitable base. This curving apparatus consistsessentially of a heating base indicated as an entirety as S, havingcurved base section 18 suitably heated as conventionally shown by thegas cock 21. Suitable cooling facilities are again provided as for theleveling apparatus by means of the openings to the cored out section ofthe base S wherein 24 indicates the inlet for cooling water and 25 is anoutlet opening. The matrix is placed with its face in the desiredposition between the platens 18 and 23 and is heated until the desiredtemperature is reached. This for foundry type metal will be between 400and 500 F. It will be found that the matrix has assumed its curved formand that a slight pressure from platen 23 will cause the matrix toassulne the curve provided for by the concave section 23 andthe convexplaten section 18. For some purposes a resilient blanket (not shown) maybe interposed between the face of the matrix 18 and the convex platill)on 18 in order that irregularities may be taken up.

It will, of course, be understood that instead of producing the usualtype of relievo plate matrices by this process, I may produce intaglioplate matrices by the use of suitable originals or by means of the ordinary expedients such as, for example, inversion. The process isalso-useful for the reproduction of printing plates and matrices of theordinary solid tint type, in which case either or both surfaces may beconsidered as the Workingface. While I have herein shown and describedcertain preferred embodiments of my invention, I wish it to beunderstood that I do not confine myself to all of the precise detailsherein set forth, as modifications and variations may be made withoutdeparting from the spirit of the invention or exceeding the scope of theappended claims. Although I .have stated in the preceding portion of thespecification that the air nozzle A-is furnished with a supply of heatedair by being conducted through pipe 10 and through heater coils 11, itshould be understood that in certain conditions it may be possible to.dispense with the heating of this air, in which case the source of heat12 maybe merely omitted. This is true of certain metals. or alloyscapable of absorbing a larger amount of heat or having a higher meltingpoint, and in this case a fair grade of sprayed work I may be producedwithout the use of the hot dry air. The dimensions of the nozzles S and5 A should be suitable to take'care of the type of metal used. Where thedimensions given are for type founders metal, other alloys or metals mayrequire certain variations in these dimensions. However, it will befound preferable in all cases to have the nozzle A of larger diameterthan the nozzle S.

lVhat I claim is 1. A printing plate matrix having a type forming faceof smooth non-homogeneous sprayed metallic particles. l

2. A printing plate matrix having a type forming face of smoothnon-homogeneous l sprayed particles and a metallic support or body forthe face portion.

3. 'A printing plate matrix having a type forming face of smoothnon-homogeneous sprayed particles and a body portion or support alsocomprising sprayed non-homogeneous metallic particles.

4. A printing plate matrix having a type forming face of smooth,non-homogeneous sprayed particles supporting a working face l of a hard,tough metal and being supported by a backing portion of metallic alloy.

5. A printing plate matrix comprising a type forming face of a hard,tough metal supported bya backing portion of non-homogeneous sprayedmetallic particles.

6. A printing plate matrix having a print-' ing face of non-homogeneous,sine-stir. porous, sprayed metal and abacking or body portion of coarsermetallic particles.

7; A printing plate matrix having aworking face of a hard air-resistingmetal, a support therefor of finely sprayed metallic particles, and asuitable backing therefor.

8. The herein described method of making a printing platematrix whichconsists in providing a suitable original and subjecting the same to aspray of metallic particles to produce a relatively thin, smooth butporous metallic deposit, cooling said deposit before each subsequentapplication of sprayed metal until a body of suitable thickness isproduced, and then separating the matrix from the original.

9. The herein described method of making a printing plate matrix whichconsists in providing a suitable original and supporting the same in thezone of a metallic spray at a predetermined distance from the spraynozzle, moving said original to expose a fresh surface to the action ofthe spray while uniformly maintaining the predetermined distance betweenthe spray nozzle and original while applying a substantially uniformfilm of smooth non-homogeneous sprayed metal, and applying successivefilms in this manner until a printing plate matrix of suitable thicknessis formed, separating the matrix so produced and leveling the same.

10. The herein described method of making a printing plate matrix whichconsists in providing a suitable original having applied thereto awax-like or adherent surface and exposing the same to the action of ametallic spray to reproduce a non-homogeneous matrix face having theregularities and irregu-* larities of the original and then separatingthe matrix from said original.

11. The herein described method of making a printing plate matrix whichconsists in exposing a suitable original in the zone of a fine metallcspray to reproduce a line, closely formed but non-homogeneous printingplate forming surface and subsequently exposing the back of said matrixto the action of a relatively coarse metallic spray to obtain a moreplastic, flexible andporousbody portion.

12. The herein described method of making a printing plate matrix whichconsists in exposing a suitable original in the zone. of a fine metallicspray to reproduce a non-homogeneous hard, tough, wear-resisting workingface and subsequently applying to the back of said type forming face arelatively less tough body or backing portion.

metallic spray to form a type forming face and a suitable body portiontherefor and subsequently depositing a tough Wear-resisting metallicfilm on the type forming face of said matrix.

14. The herein described method of making a printing plate matrix whichconsists in ex posing a suitable original in the zone of a metallicspray, said spray being composed of an alloy of metals and reproducingthe typeforming and non-type-forming surfaces in the original in theform of a matrix having a non-homogeneous metallic face and having abody portion of great flexibility when heated below the melting point ofthe alloy used.

1 5. The herein described method of making a printing plate matrix whichconsists in exposing a suitable original in the zone of a metallicspray, oxidizing the metallic particles as they are projected againstthe original and subsequently against previously deposited sprayed metalto form a matrix of great flexibility and plasticity when subquentlyheated.

16. The herein described method of making a printing plate matrix whichconsists in exposing a suitable original in the zone of a metallic sprayprojected by the aid of preheated air to prevent the chilling of theparticles and to remove any free moisture from the compressed air, andforming thereby the face and body portion of said printing plate matrix.

17. The herein described method of maleing a printing plate matrix whichconsists in exposing a portion of a suitable original in the zone of ametallic spray, applying a thin metallic coating while moving the metalcoated original toward the zone of a cool air nozzle to quickly cool themetallic tilm previously applied.

Signed at Philadelphia, in the county of Philadelphia and State ofPennsylvania this 5th day of November A. D. 1926.

EMIL E. NOVOTN Y.

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